Head guard with coupled padding layer

ABSTRACT

A head guard is provided which has a fabric layer and a padding layer. The padding layer can be attached to the fabric layer. The head guard is stretchable between a relaxed configuration and an expanded configuration. The expanding configuration has a convex shape such that it can conform to a head of a wearer. The head guard can be worn by a wearer in combination with a helmet.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/441,875, entitled “HEAD GUARD WITH COUPLED PADDING LAYER,” filed Feb.24, 2017, which is a continuation-in-part of U.S. patent applicationSer. No. 14/155,736, entitled “HEAD GUARD,” filed Jan. 15, 2014, whichis a continuation of U.S. patent application Ser. No. 14/076,615, nowU.S. Pat. No. 8,997,265, entitled “HEAD GUARD,” filed Nov. 11, 2013,which is a continuation of U.S. patent application Ser. No. 13/750,300,now U.S. Pat. No. 8,613,114, entitled “HEAD GUARD,” filed Jan. 25, 2013,which claims the benefit of U.S. Provisional Patent Application Ser. No.61/675,566, entitled “HEAD GUARD,” filed Jul. 25, 2012, the disclosuresof which are incorporated herein by reference in their entirety.

U.S. patent application Ser. No. 15/441,875 also claims the benefit ofU.S. Provisional Patent Application Ser. No. 62/299,619, entitled “HEADGUARD WITH COUPLED PADDING LAYER,” filed Feb. 25, 2016, the disclosureof which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The systems and methods described below relate generally to the field ofhead protection. More particularly, the systems and methods relate tohead guards that can be worn during sporting, or athletic, or otherphysical endeavors.

BACKGROUND

When an individual participates in contact sports activities such asfootball, lacrosse, hockey, and the like, or other physical activities,such as skiing, skateboarding, and the like, it is common that parts ofthe individual's body are subject to impact and other physical contact.Various attempts have been made to provide padding as a means ofprotecting the individual during such activities. Conventionalprotective equipment can include, as nonlimiting examples, helmets,shoulder pads, thigh pads, and shin pads. Typical protective equipmentmay include reinforced-sponge type padding, such as a rubber spongelayer laminated with a stiff plastic layer.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will be more readily understood from a detaileddescription of some example embodiments taken in conjunction with thefollowing figures:

FIGS. 1-3 show example head guards used in combination with examplehelmets.

FIGS. 4-16C are perspective views of example head guards.

FIG. 17A shows a side view of an example head guard.

FIG. 17B shows a cross-sectional view taken along line 17B-17B of FIG.17A.

FIG. 17C is an enlarged view of the encircled portion of FIG. 17B.

FIG. 18A is a perspective view of an example head guard.

FIG. 18B shows a side view of the head guard of FIG. 18A.

FIG. 18C shows a cross-sectional view taken along line 18C-18C of FIG.18B.

FIGS. 19-21 show example arrangements of padding within example headguards.

FIG. 22 shows a cross-sectional view of a head guard in accordance withone non-limiting embodiment.

FIG. 23 shows an exploded view of a head guard in accordance with onenon-limiting embodiment.

FIG. 24 depicts the head guard of FIG. 23 being positioned on the headof a wearer and stretching from a relaxed configuration to an expandedconfiguration.

FIG. 25 shows an exploded view of a head guard in accordance with onenon-limiting embodiment.

FIGS. 26A-27B show example baseball hats that incorporate a head guard.

FIG. 28-29 show example having a non-stick external surface.

FIGS. 30-34A show example winter hats that incorporate a head guard.

FIG. 34B shows a cross-sectional view of the winter hat of FIG. 34A.

FIG. 35 shows an example hooded apparel that incorporates a head guard.

FIGS. 36-37 show examples hoods that incorporate a head guard.

FIG. 38 shows a head guard for placement on the outside of an examplehelmet.

FIG. 39 shows an example head guard positioned on an example helmet.

FIG. 40 shows another example head guard positioned on an examplehelmet.

FIG. 41 shows a cross-sectional view of a head guard in accordance withone non-limiting embodiment.

FIG. 42 shows a perspective view of an example head guard.

FIG. 43 depicts a cross-sectional view of the head guard of FIG. 42taken along line 43-43.

FIG. 44 depicts an example head guard in a relaxed state and an expandedstate.

FIGS. 45A, 45B, 46A, and 46B depict example arrangements of paddinglayers for dome-shaped head guards.

FIGS. 47-53 depict cross-sectional views of example head guards toillustrate example techniques for coupling layer(s).

FIGS. 54-55 depict example of textured, non-planar padding layerscoupled to an outside surface of a head guard.

FIGS. 56-58 depict example padding layers in accordance with variousnon-limiting embodiments

DETAILED DESCRIPTION

Various non-limiting embodiments of the present disclosure will now bedescribed to provide an overall understanding of the principles of thestructure, function, and use of the head guards disclosed herein. One ormore examples of these non-limiting embodiments are illustrated in theaccompanying drawings. Those of ordinary skill in the art willunderstand that systems and methods specifically described herein andillustrated in the accompanying drawings are non-limiting embodiments.The features illustrated or described in connection with onenon-limiting embodiment may be combined with the features of othernon-limiting embodiments. Such modifications and variations are intendedto be included within the scope of the present disclosure.

The presently disclosed embodiments are generally directed to headguard, head guard systems, methods of using a head guard, and methods ofmanufacturing head guards. Such systems and methods may be implementedin a wide variety of contexts and applications. In one exampleembodiment, the head guard is compressive so that it can be retained ona user's head without the use of a securing strap, such as a chinstrap.The head guards can be constructed with one or more layers, sections, orpockets of impact absorbing or impact dissipating materials, referred togenerally herein as padding. The particular type of padding can varybased on a variety of factors, such as style of head guard, sporting orathletic application, type of user, size of head guard, and so forth. Asdescribed in more detail below, in some embodiments, the head guard canhave three layers, including an inner layer, a middle layer, and anouter layer. The middle layer can comprise the padding. Otherembodiments of head guards can have more than three layers or less thanthree layers. The head guard can comprise, for example, one or morethermal layers or at least portions of thermal protection (e.g., aroundthe ears). Such embodiments can be useful for wearers participating incold-weather endeavors. In some example embodiments, the head guard canbe washable without necessarily removing the padding layer from the headguard. The head guard can also have breathable characteristics, sweatwicking characteristics, or other comfort related characteristics, suchas vents. The head guard can have water resistant or water repellantqualities. In some embodiments, the head guard can include ananti-bacterial agent, anti-microbial agent, anti-odor agent, or otherdeodorizing or sanitizing compounds. In some embodiments, the head guardis configured to provide protection against ultraviolet rays using anysuitable techniques, such as chemical treatments, constructiontechniques, materials, and so forth. As described in more detail below,the head guard can be sized for a child wearer or an adult wearer.

In some embodiments, as described in more detail below, the head guardmay be worn underneath a wide variety of helmets, such as footballhelmets, batting helmets, bicycle helmets, and so forth. In someembodiments, the head guard may be incorporated into, formed with, orotherwise coupled to various head coverings, such as a baseball hat, awinter hat, a hood on a sweatshirt or jacket, or other styles of hat. Insome embodiments, the head guard can be incorporated into apparel (hats,hoods, and so forth) in a discrete fashion, such that it is notnecessarily apparent from an observer that the apparel includes the headguard.

In some embodiments, as described in more detail below, the head guardmay be worn over top of a wide variety of helmets, such as footballhelmets, batting helmets, skateboarding helmets, snowboarding helmets,and so forth.

As is to be appreciated, the head guard described herein can be sized toaccommodate different ages of users. In one example embodiment, achild's “one size fits all” head guard is sized to fit children and anadult's “one size fits all” head guard is sized to fit adults. Asdescribed in more detail below, elastic components incorporated into thehead guard can aid in maintaining the head guard on a user's head whilealso allowing the head guard to accommodate different sized heads. Insome embodiments, head guards can be manufactured in different sizes(small, medium, large, x-large, and so forth). In some embodiments, thehead guard may be selectively adjustable to accommodate different headsizes.

Reference throughout the specification to “various embodiments,” “someembodiments,” “one embodiment,” “some example embodiments,” “one exampleembodiment,” or “an embodiment” means that a particular feature,structure, or characteristic described in connection with the embodimentis included in at least one embodiment. Thus, appearances of the phrases“in various embodiments,” “in some embodiments,” “in one embodiment,”“some example embodiments,” “one example embodiment, or “in anembodiment” in places throughout the specification are not necessarilyall referring to the same embodiment. Furthermore, the particularfeatures, structures or characteristics may be combined in any suitablemanner in one or more embodiments.

Referring now to FIGS. 1-3 , example embodiments of the presentdisclosure show head guards are used in combination with various examplehelmets. Referring first to FIG. 1 , a head guard 100 is positionableupon a head 102 of a user. As described in more detail below, the headguard 100 can include a plurality of layers which includes a paddinglayer. The head guard 100 can be generally compressive such that itsposition on the head 102 can be maintained without the use of chinstrap. Other embodiments, however, can use additional fasteningfeatures. The head guard 100 in FIG. 1 comprises an elastic member 106which aids in securing the head guard 100 to the head 102. The elasticmember 106 may encircle the entire head guard (as shown) or may belimited to certain portions of the head guard, such as the front and/orrear. The elastic member 106 can comprise, for example, an elastic bandor cord positioned in a hem. Subsequent to placing the head guard 100 onthe head 102, a helmet 104 can be placed onto the head 102 and over topof the head guard 100. The head guard 100 can be relatively thin ascompared to the helmet 104 such that the head guard 100 does notinterfere with the usability and comfort offered by the helmet 104. Asillustrated, helmet 104 is a football helmet. It is noted that thepresent disclosure is not limited to football helmets. Instead, a widearray of different helmets can be used in in combination with the headguard 100, such as helmets worn by pilots, firemen, constructionworkers, or by any other person wearing any type of helmet or headprotection. FIG. 2 , for example, illustrates a motocross helmet 124 fora head 122 of a user. A head guard 120 can be positioned over the head122 and under the motocross helmet 124. In the illustrated embodiment,the head guard 120 comprises a neck panel 126. As is to be appreciated,any suitable configuration of head guard can be used with any suitablehelmet. Similar to the head guard 100, the head guard 120 also comprisesan elastic member 126 which generally aids in retaining the head guard120 on the head 122 of the user. In some embodiments, drawstrings,buckles, or other tightening features may be used.

As is to be appreciated, the particular configuration of the head guardcan be based on, for example, the type of helmet to be worn with thehead guard and/or the type of activity to be performed while wearing thehead guard. FIG. 3 , for example, illustrates an example head guard 130for use with a bicycle helmet 134. The head guard 130 can be placed on ahead 132 of the user prior to securing the bicycle helmet 134 to thehead 132. In the illustrated embodiment, the compressive nature of thehead guard 130 generally maintains the placement of the head guard 130on the head 132 without the use of an additional elastic feature. Whilea football helmet, motocross helmet, and bicycle helmet are illustratedin FIGS. 1-3 , the present disclosure is not limited to these particularapplication types. Instead, the head guards described herein can be usedin combination with any suitable helmet type or form of head protection.

FIGS. 4-16 illustrate non-limiting examples of head guardconfigurations. As is to be appreciated, features of head guards of someembodiments can be incorporated into the head guards of otherembodiments without departing from the scope of this disclosure. Headguard 200 in FIG. 4 , for example, is comprised of a circumferentialpanel 202, sometimes referred to as a sidewall, and a plurality of toppanels 204. The top panels 204 can be generally triangular such that,when they are coupled to each other, they generally form a disc. Asdescribed in more detail below, various types of padding can beincorporated into one or more of circumferential panel 202 and one, morethan one, or none of the top panels 204. While FIG. 4 shows an elasticmember 206 coupled to the circumferential panel 202, other embodimentsmay use other types of retention features. For example, elasticcharacteristics of the circumferential panel 202 may be used to maintainthe head guard 200 on the head of a user. As with other head guardsdescribed herein, the size of the head guard 200 can be designed suchthat it is appropriate for the particular type of user (child, teenage,adult, and so forth).

Head guard 220 illustrated in FIG. 5 shows an embodiment that does notcover the top of a user's head. Instead, the top of the head guard 220is open (e.g., a band-like configuration). The head guard 220 can beused, for example, for non-contacting sports. For instance, it can beworn by a soccer player who may frequently use the top of their head tocontact the soccer ball. Other examples of non-contacting sports caninclude, without limitation, basketball, running, volleyball, or anyother sport or endeavor that does not necessarily utilize a rigidhelmet. While the head guard 220 is shown constructed of a plurality ofpanels 224, other constructions techniques may be utilized withoutdeparting from the scope of the present disclosure. FIG. 6 shows yetanother embodiment of a head guard 240 in accordance with the presentdisclosure. The head guard 240 shown in FIG. 6 includes a rear aperture242. A wearer of the head guard 240 that has a pony tail can pull thepony tail through the rear aperture 242. The aperture 242 can have anysuitable dimension or configuration. In one embodiment, the aperture 242has a diameter in the range of about 1″ to about 3″. While the aperture242 is illustrated as being circular, it is to be appreciated that anysuitable shape can be used, such as rectangular, oblong, triangular, andso forth. Referring now to FIG. 7 , a head guard 260 is shown havingtemple guards 262. The head guard 260 also has a tightening feature 264.In the illustrated embodiment, the tightening feature 264 is a strap 266that is fixed to the head guard at a fixed end and comprises ahook-and-loop fastener assembly 268 at the other end. A user canselectively attach and detach the hook-and-loop fastener assembly 268 toselect an appropriate fit for the head guard 260. FIG. 8 shows yetanother embodiment of a head guard 270 in accordance with the presentdisclosure. The head guard 270 shown in FIG. 8 includes a rear aperture272. A wearer of the head guard 270 that has a pony tail can pull thepony tail through the rear aperture 242. The aperture 272 shown in FIG.8 is a slot or slit in a vertical orientation. In other embodiments, theaperture 272 can be a slot or slit in a horizontal orientation, anoblique orientation, or a plurality of slots or slits arranged in asuitable formation, for example.

The head guard 210 shown in FIG. 9 comprises a sidewall 212 and a toppanel 214. The sidewall 212 can be a multi-layered sidewall comprisingat least one fabric layer and at least one padding layer, as describedin more detail below. The top panel 214 can also comprises at least onefabric layer and at least padding layer. In the illustrated embodiment,the top panel 214 is attached to the sidewall 212 using stitching 216,although any suitable attachment technique can be used, such as agluing, heat welding, and so forth. The head guard 210 also comprises anelastic portion 218 that is positioned proximate to an opening definedby the sidewall 212. The head guard 210 can be in a generallycylindrical shape when in a relaxed configuration (as shown). When thehead guard 210 is placed on the head of a wearer, however, the top panel214 and the sidewall 212 can stretch to generally conform to the shapeof the wearer's head. Accordingly, the head guard 210 can stretch to aconvex-shaped configuration, which may be referred to as hemispherical,when being worn by a user. In its stretched configuration, the headguard 210 delivers a compressive force to the wearer's head in order tosubstantially maintain the position of the head guard 210 relative tothe wearer's head.

FIG. 10 illustrates a head guard 230 that defines an aperture 235. Aswith other embodiments, the aperture 235 is not limited to anyparticular configuration. In fact, a wide variety of apertureconfigurations can be utilized, such as a horizontal slit, a verticalslit, a vertically-oriented oblong opening, a horizontally-orientedoblong opening, a circular opening, or a rectangular opening, forexample. The head guard 230 comprises a sidewall 232 and a top panel234, each with an internal padding layer 236, 238. The padding layer 236of the sidewall 232 extends circumferentially about the head guard witha gap that is aligned with the aperture 235. FIG. 11 illustrates a headguard 250 that comprises a sidewall 252 and a top panel 254. Similar toother embodiments, at least one of the sidewall 252 and the top panel254 can comprise a padding layer. In this embodiment an aperture 255 isdefined by the sidewall 252 and the top panel 254. Such configuration ofthe aperture 255 may be desirable, for example, to a wearer havingdreadlocks. When the head guard 250 is placed on that wearer's head, thedreadlocks can be routed through the aperture 255.

FIG. 12 illustrates a head guard 280 having a band-like configuration,as it does not include a top panel. A sidewall 282 comprises a paddinglayer 286 that extends circumferentially about the head guard 280 and anelastic portion 284 positioned proximate to an opening defined by thesidewall 282. The head guard 280 defines an aperture 285. Asillustrated, the padding layer 286 is configured to have a gap whichaligns with the aperture 285. While the head guard 280 in FIG. 12 hasone elastic portion 284, other embodiments can utilize additionalelastic portions, as illustrated by the head guard 290 in FIG. 13 , forexample. The head guard 290 has a band-like configuration, with a topopening and a bottom opening defined by a sidewall 292. A first elasticportion 294 is positioned proximate to the top opening and a secondelastic portion 296 is positioned proximate to the bottom opening. Headguards having a band-like configuration can be worn by a user, forexample, participating in a non-contact sport or other type ofnon-contact physical endeavor.

In some embodiments, additional components can be incorporated into thehead guard. The head guard 213 illustrated in FIG. 14 , for example,includes a brim 215 that is attached to a sidewall 217. While the headguard 213 is shown with a top panel 219, other band-like embodiments canalso include a brim 215. Further, the brim can be in any suitablearrangement, such as a generally rigid visor having a cardboard core ora relatively soft visor, such as a lip comprised of fabric, or any othersuitable type of bill.

FIG. 15 illustrates yet another example embodiment of a head guard 233.The head guard 233 comprises a side wall 237 which can include a paddinglayer and a top panel 239. In the illustrated embodiment, the top panel239 comprises a mesh portion to provide added airflow and ventilation toa wearer's head. Some embodiments incorporating a mesh top panel 239utilize a top padding layer, while others do not. Additionally, oralternatively, the sidewall 237 can be mesh, or at least comprise one ormore portions that are mesh or otherwise provide air flow to the wear.

The particular orientation, location, and/or placement of the paddinglayer can vary. In some embodiments, for example, the padding layer ispositioned within a pocket defined by two fabric layers. In otherembodiments, the padding layer can be exposed, either internally orexternally. FIG. 16A-16C illustrate example configurations of a headguard 281 that includes an external side padding layer 283 and anexternal top padding layer 288. The side padding layer 283 is attachedto a side panel 287 to collectively define a sidewall and the toppadding layer 288 is coupled to a top layer 289 to collectively define atop panel. FIG. 16A illustrates that the side padding payer 283 and thetop padding layer 288 can be of unitary construction. FIG. 16Billustrates that the side padding payer 283 and the top padding layer288 can be a collection of individual modules or pods that are attachedto the top layer 289 and the side panel 287. FIG. 16C illustrates thatthe side padding payer 283 and the top padding layer 288 can bestitched, or otherwise moulded or shaped to form a pattern. As is to beappreciated, any suitable technique can be used to couple the paddinglayers to the head guard 281, such as using stitching or usingadhesives, such as glue, for example. In some configurations, an entiresurface of the padding layer is coupled to the side panel, whereas inother configurations, only a portion of the padding layer (such as theperimeter) is coupled to the side panel. Additional examples of headguards having padding layers that are stitched, laminated, or otherwisecoupled are described in more detail in FIGS. 42-58 .

It is noted that while various head guards are illustrated having anelastic member around the lower periphery, such elastic members are notnecessary for some configurations. Instead, the head guard can havecompressive qualities or characteristics that maintain the head guard onthe wearer's head. In other words, some or all of the head guard can bemanufactured from stretchable materials that allow the head guard tostretch when placed on the head of a user and contract when removed fromthe head of a user. In some embodiments, the head guard can have one ormore elastic members or portions and can also be stretchable.

Referring now to FIGS. 17A-17C, a head guard 300 in accordance with onenon-limiting embodiment is shown. FIG. 17A shows a side view of the headguard 300 which has an elastic member 302 positioned around its lowerperiphery. The elastic member 302 can be an elastic band positionedinside a hem, for example. In some embodiments, an elastic member can befed through hoops or other retention members. FIG. 17B shows across-sectional view of the head guard 300 taken along line 17B-17B ofFIG. 17A. FIG. 17C shows an enlarged view of the encircled area of FIG.17B and illustrates various layers of the head guard 300. As shown inFIGS. 17A-17C the head guard 300 of the illustrated embodiment comprisesan outer layer 320, a padding layer 340, and an inner layer 360. In someembodiments, the head guard may be constructed with only an outer layerand padding layer, while in other embodiments the head guard may beconstructed with only a padding layer and inner layer. Further, in someembodiments, the padding layer 340 is disconnected from each of theinner layer 360 and the outer layer 320. In some embodiments, thepadding layer 340 is coupled to one or both of the inner layer 360 andthe outer layer 320.

The head guard 300, or other head guards described herein, can define aninternal diameter “D” (FIG. 17B), which can be selected to accommodate aparticular type of user, such as a child, an adult, a person with a lotof hair, a person with short hair, and so forth. Thus, in certainembodiments, the head guard 300 can be manufactured to accommodate achild's head. In other embodiments, the head guard 300 can bemanufactured to accommodate an adult's head. In other embodiments, thehead guard 300 can be configured to accommodate both smaller-sized headsand larger-sized heads. In some embodiments, the value of “D” for adulthead guards can be based on Table 1, below, and the value of “D” forchild head guards can be based on Table 2, below.

TABLE 1 Adult Head Guard Example Sizes Diameter Stretch Fit/ “D” SizeAdjustable 6¾ Small 6⅞ (S) 7 Medium One Size 7⅛ (M) Fits Most 7¼ Large7⅜ (L) 7½ XL 7⅝ 7¾ XXL 7⅞ 8

TABLE 2 Child Head Guard Example Sizes Diameter Stretch “D” Size FittedKids 6 XSM Infant 6⅛ S Toddler 6¼ S/M 6⅜ M Child 6½ 6⅝ L L/X Youth 6¾ 6⅞XL 7

The padding layer utilized by head guards in accordance with the presentdisclosure can be comprised of any suitable material that provides thedesirable characteristics and response to impact. For example, thepadding layer can comprise one or more of the following materials:thermoplastic polyurethane (available, for example, from SkydexTechnologies), military-grade materials, impact absorbing silicone, D30®impact absorbing material, impact gel, wovens, non-wovens, cotton,elastomers, IMPAXX® energy-absorbing foam (available from DowAutomotive), DEFLEXION shock absorbing material (available from DowCorning), styrofoam, polymer gels, general shock absorbing elastometers,visco-elastic polymers, PORON® XRD impact protection (available fromRogers Corporation), Sorbothane® (available from Sorbothane Inc.),Neoprene (available from DuPont), Armourge®I energy absorbing material(available from Armourgel Ltd.) Ethyl Vinyl Acetate, impact-dispersinggels, foams, rubbers, and so forth. The padding layer can be breathableand/or generally porous to provide ventilation. In some embodiments, thepadding layer is a mesh material that aids in the breathability of theassociated head guard. In some embodiments, the padding layer isperforated, slitted, or otherwise comprises one or more apertures oropenings. Such structure can aid in breathability of the associated headguard, for example. The padding layer can be attached to one or morelayers (such as the outer layer 320 and the inner layer 360 of FIG. 17C,for example). In some embodiments, the padding layer 340 can begenerally disconnected and “floating” between the layers. In someembodiments, the padding layer is attached to an elastic member or otherportions of the head guard.

In some embodiments, padding layers in accordance with the presentsystems and methods can comprise a rate dependent material, such as arate dependent low density foam material. Examples of suitable lowdensity foams include polyester and polyether polyurethane foams. Insome embodiments, such foams to have a density ranging from about 5 toabout 35 pounds per cubic foot (pcf), more particularly from about 10 toabout 30 pcf, and more particularly still from about 15 to about 25 pcf.PORON® and PORON XRD® are available from Rogers Corporation, which areopen cell, microcellular polyurethane foams, is an example of onesuitable rate dependent foam. However, in order to provide impactresistance, the padding layer can be any suitable energy absorbing orrate dependent materials. As such, other rate dependent foams or othertypes of materials can be used without departing from the scope of thepresent disclosure.

The other layers of head guards in accordance with the presentdisclosure can either be the same material or different material. Thematerial can be, for example, and without limitation, polyester, nylon,spandex, ELASTENE (available from Dow Chemical), cotton, materials thatglow in the dark or are fluorescent, and so forth. Either of the inneror outer layers can also be of a mesh or otherwise porous material. Insome embodiments, the inner and/or outer layers can be a blend of avariety of materials, such as a spandex/polyester blend. In someembodiments, the head guard is water proof, water resistant, or waterrepellant. Other durable materials can be used for the outer layer ofany embodiment, including knit, woven and nonwoven fabrics, leather,vinyl or any other suitable material. In some instances, it can bedesirable to use materials for the layer than are somewhat elastic;therefore, stretchable fabrics, such as spandex fabrics, can bedesirable. Such materials can help provide compressive forces tomaintain placement of head guard on a wearer's head without the need fora chin strap, for example.

Various head guards in accordance with the systems and methods describedherein can be manufactured with or otherwise include various coatings,agents, or treatments to provide anti-microbial or anti-bacterialproperties. Some embodiments, for example, can utilize Microban® offeredby Microban International, Ltd. for antibacterial protection. In someembodiments, the padding layer comprises antimicrobial agents and one ormore other fabric layers of the head guard also treated withantimicrobial agents. Antimicrobial protection for the fabric layers canbe in the form of a chemical coating applied to the fabric, for example.Generally, antimicrobial technologies combat odor by fighting bacteriaresulting in fresher smell for longer and minimizing the frequency oflaundering or washing. Any suitable technique can be used to providehead guards with antimicrobial properties. In one embodiment, forexample, AEGIS Microbe Shield® offered by DOW Corning Corp. is utilized.Other examples of antimicrobial agents include SILVADUR® offered by TheDow Chemical Company is utilized, Smart Silver offered by NanoHorizons,Inc., and HealthGuard® Premium Protection offered by HealthGuard.

In some embodiments, a head guard, or at least various components of ahead guard are configured to provide moisture wicking properties.Generally, moisture wicking translates into sweat management, whichworks by removing perspiration from the skin in an attempt to cool thewearer. Any suitable moisture wicking can be used. In one embodiment, atopical application of a moisture wicking treatment to a fabric of thehead guard is utilized. The topical treatment is applied to give thehead guard the ability to absorb sweat. The hydrophilic(water-absorbing) finish or treatment generally allows the head guard toabsorb residue, while the hydrophobic (water-repellent) fibers of thehead guard help it to dry fast, keeping the wearer more comfortable. Inone embodiment, the blend of fiber is used to deliver moisture wickingproperties by combining a blend of both hydrophobic (such as polyester)with hydrophilic fibers. Certain blends of these fibers allow thehydrophilic fibers to absorb fluid, moving it over a large surface area,while the hydrophobic fibers speed drying time. One benefit of headguards utilizing these types of fiber blends is that moisture managementproperties are inherent in the fiber blend, meaning they will never washor wear out.

FIGS. 18A-18C illustrate a head guard 400 in accordance with variousnon-limiting embodiments. FIG. 18A is a perspective view of the headguard 400, which comprises a plurality of panels 402. The panels 402 canbe arranged such that the head guard 400 is generally a convexshape.FIG. 18B is a side view of the head guard 400 and FIG. 18C is across-sectional view of the head guard 400 of FIG. 18B taken along line18C-18C. As shown in FIG. 18C, each panel 402 may include an innerpocket. Padding 420 can be positioned within the inner pocket of eachpanel 402. In some embodiments, padding 420 can semi-rigid (such asStyrofoam), while other embodiments can utilize flexible or generallypliable padding 420. As is described in more detail below with referenceto FIGS. 47-53 , in some configurations, the padding 420 can be coupledto various portions of the panel 402.

The arrangement or placement of the padding within the head guard canvary. FIGS. 19-21 illustrate non-limiting embodiments of head guardshaving a variety of padding orientations. The head guard 500 shown inFIG. 19 , for example, shows a padding layer 502 that is generallyconvex-shaped. The head guard 520 shown in FIG. 20 shows a first padding522 positioned at a first position and a second padding 524 positionedat a second position. The head guard 540 shown in FIG. 21 shows aplurality of different padding layer types arranged at various positionson the head guard 540. As illustrated, a first padding is positioned atfirst padding layer 542 and a second padding is positioned at secondpadding layer 548. A third padding is positioned at third padding layer546. The third padding layer 546 can be, for example, a different typeof padding material than the padding material of the first and secondpadding layers 542, 548. The first and second padding layers 542, 548can be a semi-rigid padding (such as Styrofoam) while the third paddinglayer 546 is can be a pliable or semi-pliable layer. In someembodiments, the placement or configuration of the padding can depend onthe type of helmet a user may wear in combination with the head guard.The padding layers 502, 522, 542, 546, and 548 can be any suitable typeof material, such as, without limitation, one or more of the materialsdescribed above with reference to padding layer 340.

FIG. 22 illustrates a cross-sectional view of a head guard 600 inaccordance with one non-limiting embodiment. The head guard 600comprises an outer layer 602, and inner layer 606, and a padding layer608. Each of the layers can be manufactured from a wide variety ofmaterials, as described above. The overall thickness (D1) of the headguard 600 can vary based on application. In some embodiments, forexample, D1 can be in the range of about 0.1″ to about 0.5″. In someembodiments, for example, D1 can be in the range of about 0.5″ to about1.0″. In some embodiments, for example, D1 can be larger than about1.0″. The thickness can be based on, for example, the type of helmetworn with the head guard (if any), the type of sport being played whilewearing the head guard, or characteristics of the wearer. While FIG. 22shows three layers, this disclosure is not so limited. As is to beappreciated, in some embodiments, head guards can have more or lesslayers. For example, various head guards may not utilize an inner layer.In any event, FIG. 22 shows the respective thicknesses of the outerlayer 602 (D2), the padding layer 608 (D3), and the inner layer 606(D4). In some embodiments, each of D2, D3, and D4 are generally equal.In some embodiments, D2 and D4 are generally equal while D3 differs. Insome embodiments, two of the layers have similar thickness while thethird layer differs. In some embodiments, all three layers havedifferent thicknesses. In any event, D2, D3, and D4 can each be anysuitable thickness. For example, the thickness of any layer can be lessthan about 0.01″, the thickness of any layer can be in the range ofabout 0.01″ to about 0.125″, or the thickness of any layer can be inrange of about 0.125″ to 0.5″. In some embodiments, the thickness of anylayer can be greater than 0.5″. Moreover, in some embodiments, thethickness of the padding layer is greater than about 30% of thethickness D1. In some embodiments, the thickness of the padding layer isgreater than about 50% of the thickness D1. In some embodiments, thethickness of the padding layer is greater than about 70% of thethickness D1. In some embodiments, the thickness of the padding layer isgreater than about 90% of the thickness D1. In some embodiments, thethickness of the padding layer is greater than about 99% of thethickness D1.

In some embodiments the padding layer 608 is disconnected from the outerlayer 602 and inner layer 606, such that it is generally “floating”between the two. In other embodiments the padding layer 608, or at leastportions thereof, is attached to one or both of the outer layer 602 andinner layer 606. Finally, it is noted that while FIG. 22 shows eachlayer having a generally uniform thickness, this disclosure is not solimited. In fact, the thickness of any particular layer may vary atdifferent locations of the head guard 600. For example, the thickness ofthe padding layer 608 may be thicker at a first location of the headguard 600 and thinner at a second location of the head guard 600.

FIG. 23 is an exploded view of a head guard 610 in accordance with onenon-limiting embodiment. The head guard 610 has a longitudinal axis “L”and comprises a multi-layered top panel 632 and a multi-layered sidewall634. The multi-layered top panel 632 can be attached to themulti-layered sidewall 634 using suitable stitching techniques, forexample. The multi-layered top panel 632 comprises a top fabric layer612 and a bottom fabric layer 616. The multi-layered top panel 632 canbe generally flat-shaped with the head guard 610 is in a relaxedconfiguration. The multi-layered top panel 632 can be generallyconvex-shaped with the head guard 610 is in an expanded configuration.The top fabric layer 612 and the bottom fabric layer 616 can bemanufactured from a stretchable material, as described in more detailbelow. A padding layer 614 is positioned between the top fabric layer612 and the bottom fabric layer 616. In some embodiments, the surfacearea of the padding layer 614 is slightly smaller than the surface areaof the top fabric layer 612. Furthermore, the padding layer 614 can alsobe stretchable, though not necessarily as stretchable as the top fabriclayer 612 and the bottom fabric layer 616. The top fabric layer 612 andthe bottom fabric layer 616 can cooperate to define a pocket, with thepadding layer 614 positioned in the pocket.

In the illustrated embodiment, the multi-layered sidewall 634 comprisesan inner fabric layer 618, a padding layer 620, an outer fabric layer622, and an elastic member 624. The multi-layered sidewall 634 can begenerally cylindrical-shaped with the head guard 610 is in a relaxedconfiguration. The multi-layered sidewall 634 can be generallyfrustoconically-shaped with the head guard 610 is in an expandedconfiguration. The inner fabric layer 618 and the outer fabric layer 622can be manufactured from a stretchable material, as described in moredetail below. The inner fabric layer 618 can define an aperture 619having any suitable size, configuration, or arrangement. The outerfabric layer 622 can define an aperture 623 having any suitable size,configuration, or arrangement that generally aligns with the aperture619 when the head guard 610 is an assembled configuration. Furthermore,stitching or other attachment techniques can be used to join theperiphery of the aperture 619 with the periphery of the aperture 23 inthe assembled configuration. The side padding layer 620 is positionedbetween the inner fabric layer 618 and the outer fabric layer 622. Insome embodiments, the surface area of the padding layer 620 is slightlysmaller than the surface area of the outer fabric layer 622.Furthermore, the side padding layer 620 can also be stretchable, thoughnot necessarily as stretchable as the inner fabric layer 618 and theouter fabric layer 622. The inner fabric layer 618 and the outer fabriclayer 622 can cooperate to define a pocket, with the side padding layer620 positioned in the pocket. In some embodiments, the inner fabriclayer 618 and the outer fabric layer 622 are attached in an arrangementthat forms a plurality of pockets and a padding layer is positionedwithin each pocket such that a collection of individual padding modulesor pods generally forms the padding layer. As described in more detailbelow, the side padding layer 620 can be attached to the inner fabriclayer 618 and/or the outer fabric layer 622. Similarly, the paddinglayer 614 can be attached to the top fabric layer 612 and/or the bottomfabric layer 616.

The side padding layer 620 can be the same or different material as thepadding layer 614. Further, these two layers can have the same ordifferent thicknesses. The side padding layer 620 can be any suitableshape or configuration. In the illustrated example, the side paddinglayer 620 has a top surface 621, a first end surface 630, a second endsurface 628, and a bottom surface (not shown). While the side paddinglayer 620 is illustrated as being generally rectangular andcircumferentially extending about the head guard 610, other embodimentscan utilize side padding layers 620 having different shapes. In anyevent, in the assembled configuration, the top surface 621 is positionedproximate to the multi-layered top panel 632. The first end surface 630and the second end surface 628 can be opposed and circumferentiallyspaced to define a gap 638. While the gap 638 is shown as beinggenerally rectangular, the gap 638 can have any suitable shape or size.In some embodiments, the gap 638 is positioned such that it generallyaligns with the aperture 619 defined by the inner layer 618 and theaperture 622 defined by the outer layer 622. In other embodiments, thefirst end surface 630 and the second end surface 628 are joined togetherto form a contiguous ring of padding. Moreover, in some embodiments, thepadding layer 620 can generally be a contiguous ring of padding thatalso defines an aperture therethrough. It is noted that as with otherhead guards illustrated herein, the head guard 610 shown in FIG. 23 ismerely an illustrative example embodiment. Thus, while the lowerperiphery of the head guard 610 is illustrated being flat, otherembodiments of head guards can have different shapes and configurationswithout departing from the scope of the present disclosure. For example,some embodiments of the head guard 610 can include a lower peripheryhaving a wave-like configuration, such that the side and rear part ofthe multi-layered sidewall 634 extend further from the multi-layered toppanel 632 to cover a user's ears and wrap around the back of their head,as shown in FIGS. 28-29 , for example.

FIG. 24 depicts the head guard 610 shown in FIG. 23 stretching from arelaxed configuration shown by the head guard 610A to an expandedconfiguration by the head guard 610C. As shown, head guard 610A ingenerally cylindrical in the relaxed configuration. As head guard isplaced on the head of a wearer, the multi-layered sidewall 634 begins toexpand, as shown by head guard 610B. As the head of the wearer isinserted further into the head guard, the head guard continues tostretch until it reaches an expand configuration, shown by head guard610C. As shown by head guard 610C, the multi-layered top panel 632changes from a flat shape to a convexshape when the head guard is placedon wearer's head. Additionally, the multi-layered sidewall 634 alsochanges shape in order to accommodate the wearer's head. As is to beappreciated, due to the stretchability of the head guard 610, it canaccommodate a range of head sizes and shapes. When the head guard 610Cis removed from the wearer's head, it will return to the shapeillustrated by head guard 610A.

FIG. 25 is an exploded view of a band-like head guard 650 in accordancewith one non-limiting embodiment. The head guard 650 has a longitudinalaxis “L” and comprises a multi-layered side panel 662. The multi-layeredsidewall 662 comprises an inner fabric layer 654, a padding layer 656,an outer fabric layer 658, and elastic members 652, 660. Themulti-layered sidewall 662 of the illustrated embodiment is generallyfrustoconically-shaped with the head guard 650 is in a relaxedconfiguration. As is to be appreciated, other embodiments can have othershapes in the relaxed configuration, such as cylindrical or toroidal,for example.

The inner fabric layer 654 and the outer fabric layer 658 can bemanufactured from a stretchable material, as described in more detailbelow. The padding layer 656 is positioned between the inner fabriclayer 654 and the outer fabric layer 658. In some embodiments, thesurface area of the padding layer 656 is slightly smaller than thesurface area of the outer fabric layer 658. Furthermore, the paddinglayer 656 can also be stretchable, though not necessarily as stretchableas the inner fabric layer 654 and the outer fabric layer 658. The innerfabric layer 654 and the outer fabric layer 622 can cooperate to definea pocket, with the padding layer 656 positioned in the pocket.

The padding layer 656 can be any suitable shape or configuration. In theillustrated example, the padding layer 656 has a top surface 664, afirst end surface 666, a second end surface (not shown), and a bottomsurface (not shown). In the assembled configuration, the top surface 664is positioned proximate to elastic member 652 and the bottom surface ispositioned proximate to the elastic member 660. The first end surface660 and the second end surface can be opposed and circumferentiallyspaced to define a gap 668. The gap 668 can have any suitable shape orsize. In some embodiments, the gap 668 is positioned such that it alignswith an aperture through the head guard. In other embodiments, the firstend surface 666 and the second end surface 628 are joined together toform a contiguous ring of padding. The padding layer 656 can be floatingor attached to the inner fabric layer 654 and/or the outer fabric layer658.

In some embodiments, head guards in accordance with the presentdisclosure can be integrated, incorporated, coupled to, formed with, orotherwise associated with various forms of headwear. For example, headguards can be built into baseball hats, softball hats, winter hats,cowboy hats, or other types of headwear. FIGS. 26A, 26B, 27A, and 27Billustrate baseball hats with built-in head guards in accordance withexample embodiments. Referring first to FIGS. 26A and 26B, the baseballhat 700 includes a padding layer 702 that is generally convex-shaped.While the baseball hat 700 depicted in FIG. 26B does not illustrate aninterior fabric layer, some embodiments can include an interior fabriclayer. For example, the baseball hat 700 may be constructed with threelayers, as illustrated in FIG. 22 , for example.

The baseball hat 720 of FIGS. 27A-27B comprises a plurality of panels722 that are stitched together to form the hat. As illustrated, eachindividual panel 722 includes a padding layer 724. In some embodiments,each panel 722 forms an internal pocket that houses the padding layer724. While the baseball hat 720 depicted in FIG. 27B does not illustratean interior fabric layer, some embodiments can include an interiorfabric layer. In some embodiments, the padding layer is discretelyincorporated into the baseball hat. In other words, the baseball hat canhave the general appearance of a baseball hat that does not include apadding layer. The padding layers 702 and 724 can be any suitable typeof material, such as, without limitation, one or more of the materialsdescribed above with reference to padding layer 340. As is to beappreciated, a padding layer can be incorporated (discretely orotherwise) into other types of hats, such as, golf hats, visors, cowboyhats, police hats, fireman hats, military hats or head coverings, and soforth.

As illustrated in FIGS. 28-29 , in some embodiments, a head guard cancomprise a non-stick exterior surface. The head guard 740 shown in FIG.28 comprises a multi-layer top panel 743 that is attached to (orintegral with) a multi-layer lower panel 742. Each of the multi-layertop panel 743 and the multi-layer lower panel 742 can include a paddinglayer, as described above. Further, the multi-layer top panel 743 has anexterior surface 744 and the multi-layer lower panel 742 has an exteriorsurface 746. These exterior surfaces 744, 746 can come in direct contactwith the interior surface of a helmet, or other type of head gear, whenboth pieces of gear are worn by the user at the same time. Referring nowto FIG. 29 , a head guard 760 is shown that comprises a multi-layer toppanel 765 and a multi-layer side panel 763 that is attached to amulti-layer lower panel 762. Each of the multi-layer panels 762, 763,765 can include a padding layer as described above. Further, themulti-layer top panel 765 has an exterior surface 767, the multi-layerside panel 763 has an exterior surface 764 and the multi-layer lowerpanel 762 has an exterior surface 766. These exterior surfaces 764, 766,767 can come in direct contact with the interior surface of a rigidhelmet when both pieces of gear are worn by the same user.

The exterior surfaces 744, 746, 764, 766, 767 can have non-stick (ornon-slipstick) properties that generally reduces a coefficient offriction of the exterior surface of the head guard. While a variety offriction-reducing treatments or coatings can be used to provide thenon-stick properties, in one example embodiment aPolytetrafluoroethylene (PTFE) treatment is used. Example PTFEtreatments include the Teflon polymer products from DuPont (Teflon® PTFEfluoropolymer) and Chemfab from Saint Gobain. Beneficially, PTFE alsoprovides repellency against oil- and waterbased stains, dust and dryoil. In some embodiments a topical application of a coating or film isused. In other embodiments, a PTFE fiber, such as a Teflon® PTFE fiberfrom DePont) can be integrated into the fabric (such as polyester ornylon) material mix. It is noted that in addition to other benefits, thelower panels 742, 762 can increase the amount of exterior surface areaof the head guard that is treated with the non-stick coating.

Providing an exterior non-stick surface can be beneficial when the userwears the head guard in combination with a helmet. For example, due tothe low coefficient of friction, the helmet will easily slide over topof the head guard when the user is putting on their helmet.Additionally, when the helmet receives an impact, the helmet can rotaterelative to the head guard, perhaps only slightly, but thus resulting inless rotational movement for the wearer's head due to the rotationalforce generated by the impact. It is noted that while head guards 740and 760 are configured to cover the top of a wearer's head, it is to beappreciated that similar configurations can be used for band-like headguards. As such, a band-like head guard can have non-stick propertiesand can also include a lower panel similar to those illustrated in FIG.28-29 .

FIGS. 30-33 illustrate winter headgear incorporating head guards inaccordance with various embodiments. In some embodiments, the paddinglayer is discretely incorporated into the winter hat. In other words,the winter hat can have the general appearance to an observer of awinter hat that does not include a padding layer. Referring first toFIG. 30 , winter hat 800 is an aviator style hat having insulatingproperties. A padding layer 802 is incorporated into the structure ofthe winter hat 800. The padding layer 802 can be rigid, pliable, or acombination of rigid components and pliable components. The winter hat800 can include chin straps 804 to secure the winter hat 800 to awearer. The winter hat 800 can include a plurality of layers, such as aninner fur-lined layer, a middle padding layer, and an outer fabriclayer. Additional insulating layers can also be used. Winter hat 820shown in FIG. 31 is another style of winter headgear that incorporates ahead guard. The head guard comprises a first padding layer 822 and asecond padding layer 824. The particular material for the first paddinglayer 822 and the second padding layer 824 may differ. For example, arelatively thick padding can be used for first padding layer 822 whilepadding having high insulating properties can be used for second paddinglayer 824 due to its proximity to a wearer's ears. Winter hat 820 haschin straps 826 to allow a user to securely fasten the winter hat 820 totheir head.

FIG. 32 is yet another embodiment showing a winter hat 830 that includesa first padding layer 832 and a second padding layer 834. The firstpadding layer 832 can be in a convex configuration and either be asingle unitary piece or a plurality of components that form thegenerally convexshape. In some embodiments, the first padding layer 832does not form a complete dome, but instead is localized to certainareas, such as the front and the back of the hat, for example. Asillustrated, the second padding layer 834 can be in the headband portion836. The first and second padding layers 832, 834 can be manufacturedfrom the same or different types of materials. For example, the firstpadding layer 832 can be Styrofoam while the second padding layer 834can be an impact gel. Alternatively, both the first and second paddinglayers 832, 834 can both be impact gel. FIG. 33 shows another embodimentof a winter hat 840 that comprises a padding layer 842. As is to beappreciated, the present disclosure is not limited to any particulartype or style of winter hat or winter head gear.

FIG. 34A depicts another embodiment of a winter hat 850 thatincorporates a padding layer 854. FIG. 34B is a cross-sectional view ofthe winter hat 850. The winter hat 850 can comprise a fabric layer 856that is configured to cover a wearer's head. A thermal layer 858 canhave a band-like configuration and be attached to an interior surface ofthe fabric layer to form a pocket 860. A padding layer 854 is positionedin the pocket 860. In some embodiments, the thermal layer 858 is anextension of the fabric layer 856 that is folded and stitched to createa pocket to house the padding layer 854.

Referring to FIGS. 30-34B, the padding layers 802, 822, 824, 832, 834,and 842, 854 can be any suitable type of material, such as, withoutlimitation, one or more of the materials described above with referenceto padding layer 340.

In some embodiments, head guards in accordance with the presentdisclosure can be integrated, incorporated, coupled to, formed with, orotherwise associated with various types of apparel. FIG. 35 illustratesan example embodiment of a hooded sweatshirt 900 that incorporates ahead guard in its hood. The hooded sweatshirt 900 shown in FIG. 35 isfor illustrative purposes only. In fact, the head guard could beincorporated into the hood of any form of apparel, such as a jacket, apull-over sweatshirt, a windbreaker, a winter coat, or any other articleof clothing with a hood. In any event, the hooded sweatshirt 900 has ahood 902 that includes a padding layer 904. The hood 902 can beconstructed using any suitable technique, such as the three layertechnique illustrated in FIG. 22 . The hood 902 can be sized togenerally conform closely to the wearer's head. In some embodiments, thepadding layer 904 comprises a Styrofoam or other semi-rigid core.Drawstrings 906 can be routed through a hem 908 in the hood 902. Bydrawing the drawstrings 906 downward, the hood 902 can be positioned inclose proximity to the wearer's head.

As shown in FIG. 36 , in some embodiments, a plurality of tightening oradjustment features can be used. The hood 920 in FIG. 36 comprises apadding layer 930. A first set of drawstrings 922 are positioned withina first hem 926 of the hood 920 and a second set of drawstrings 924 arepositioned within a second hem 928 of the hood 920. By selectivelydrawing the first and/or second set of drawstrings 922, 924, the hood920 can be tightened around the head of a wearer. As is to beappreciated, other forms of tightening features can be utilized, such ashook-and-loop fasteners, elastic members, cord locks, and so forth.

FIG. 37 illustrates yet another embodiment of a hood 940 incorporating apadded feature. The hood 940 comprises a first padding layer 942 and asecond padding layer 944. The second padding layer 944 is positioned sothat it is generally proximate the wearer's forehead. Drawstrings 946can be selectively drawn to tighten the hood 940 around a wearer's head.The padding layers 904, 930, 942, and 944 can be any suitable type ofmaterial, such as, without limitation, one or more of the materialsdescribed above with reference to padding layer 340.

In some embodiments, head guards in accordance with the system andmethods described herein can be worn by an athlete external to a helmet.An example head guard that can be worn on the outside of a helmet isillustrated in FIG. 38 . The head guard 1000 can be compressive, orstretchable, such that it can be placed snugly around an outside surface1006 of a football helmet 1004. In some configurations, the position ofthe head guard 1000 can be maintained through the compressivecharacteristics of the head guard 1000. In other embodiments, additionaltechniques can be utilized to attach the head guard to the helmet, suchas adhesives, straps, buckles, hook-and-loop fasteners, and so forth. Inany event, the head guard 1000 can comprise a padding layer 1002,similar to the other padding layers described herein. The head guard1000 can comprise an inner surface 1008 that is generally slip-resistantthat can aid in maintaining the proper positioning of the head guard1000, even during an impact event. The head guard 1000 can comprise anouter surface 1010 that is a material that has a relatively lowcoefficient of friction that can allow the head guard 1000 (andunderlying helmet) to generally slide across an object during impact,such as another football player. Example materials for outer surface1010 include, without limitation, polyester and nylon combinations,including spandex or elastane. The head guard 1000 can also compriseports 1012 that are positioned to generally align with the helmet port1014 when the head guard 1000 is placed over the helmet 1004. The ports1012 can be configured to generally allow sound to travel through thehead guard 1000 so that the athlete's hearing is not affected when thehead cover 1000 is positioned on the helmet 1004. As is to beappreciated, the particular design of the ports 1012 can vary in variousembodiments. For example, in one embodiment the ports 1012 can comprisea single large port, while in another embodiment the port 1012 cancomprise a series of slots.

FIGS. 39-40 show example head guards used in combination with varioustypes of sporting helmets. FIG. 39 shows a head guard 1100 coupled to afootball helmet 1110. The head guard 1100 cab be selectively removablefrom the helmet 1110 and be manufactured in different sizes toaccommodate different helmet sizes. The outer surface of the head guard1100 can be clear, a solid color, or a combination of colors. The outersurface can also include numbering, letters, words, graphics, and soforth. The head guard 1100 can also comprise one or more padded ridgesor other areas of increased padding. In the illustrated embodiment, thehead guard 1100 comprises a top ridge 1102, a rear ridge 1104, and sideridges 1106. These ridges can be unitary, or otherwise integral, withthe head guard 1100 and can be manufactured from any suitable materials,such as foam, impact gel, Styrofoam, or any other suitable impactabsorbing or dissipating materials. It is to be appreciated, that thehead guards disclosed herein can be used or configured to be worn on theoutside of a variety of helmet types. FIG. 40 , for example, shows ahead guard 1120 positioned over top of a hockey helmet 1124. The headguard 1120 comprises vents 1122 that can align with vents in the hockeyhelmet 1124. In some embodiments, the head guard 1120 can also includepadded ridges, or other areas of increased thickness or density.

FIG. 41 shows an example cross-sectional view of a head guard 1200 thatcan be positioned on the outside of a sporting helmet. The head guard1200 comprises three layers, including an outer layer 1202, a paddinglayer 1204, and an inner layer 1206. In some embodiments, fewer oradditional layers can be used. In the illustrated embodiment, the headguard 1200 also comprises ridges 1208. As discussed above, the innerlayer 1206 can have a relatively high coefficient of friction, such thatit has a tendency to adhere to or grip the outside surface of anassociated helmet. The padding layer 1202 can comprise any suitablematerials, including the variety of materials described above. The outerlayer 1202 can have a relatively low coefficient of friction as comparedto the inner layer 1206. Depending on the associated sporting event, theouter layer 1202 may be in contact with various objects, such as otherplayer's jerseys, helmets, and so forth. With the outer layer 1202having a relatively low coefficient of friction, during those impactevents, the head guard 1200 can behave similarly to the outer surface1006 (FIG. 36 ) of the underlying helmet. The head guard 1200 (with orwithout the ridges 1208) can be used in combination of a wide variety ofhelmet types, including, without limitation, baseball, hockey,bicycling, and skateboarding, for example.

In some embodiments, head guards can include a padding layer that iscoupled to at least a portion of the head guard. As used herein, coupledgenerally refers to any type of technique or mechanism for affixing,attaching, mating or otherwise temporarily or permanently mounting thepadding layer to the head guard. For example, a padding layer can becoupled to a fabric layer of the head guard. For head guards havingmultiple fabric layers (e.g., an inner layer and an outer layer) apadding layer can be coupled to the inner layer, the outer layer, orboth the inner and outer layers. The technique for coupling the paddinglayer to the various portions of the head guard can vary. In someembodiments, for example, a padding layer can be stitched, glued, heatwelded, laminated, and/or combinations thereof. The technique forcoupling the padding layer can generally interact with the entiresurface of the padding layer (e.g., adhesive-based techniques and/orlamination techniques) or interact with only a portion of the paddinglayer (i.e., stitching-based techniques). Some head guards can utilize aplurality of different coupling techniques to provide desired thefunctionality and/or durability.

A padding layer can be coupled to an outer surface of a head guard, aninner surface of a head guard, and/or positioned and coupled between twoor more fabric layers of a head guard. In some embodiments, the portionsof the fabric layer(s) coupled to the padding layer may not expand orstretch as much as the portions of the fabric layer(s) not coupled tothe padding layer. Nevertheless, the head guard can be constructed andconfigured such that compressive forces maintain the head guard on awearer's head. As described in more detail below, portions of the headguard that are not coupled to the padding layer can expand to assistwith conforming the head guard to the wearer.

In some embodiments, the padding layer can be generally rigid so thatits shape is generally maintained when the head guard is in a relaxedstate or an expanded state. For example, the padding layer can comprisea plurality of generally curved semi-rigid segments that are coupled tothe head guard. The curvature of the semi-rigid segments can be designedto generally conform to the curvature of a wearer's head.

The padding layer can have any suitable dimensions and structure. Forinstance, the padding layer can be generally planar or the padding layercan be non-planar. In some embodiments, the padding layer comprises aplurality of absorption members, such as nodules, ribs, domes, etc.,that generally extend outwardly or inwardly from the head guard. Theabsorption members can be of any suitable shape or configuration.

The padding layer and/or other layers of the head guard can bemanufactured using any of a variety of suitable manufacturingtechniques. For instance, in some embodiments, the padding layer isinjection moulded using forms (or moulds). The forms can be configuredsuch that the padding layer can be formed to include through-holes,divots, slits, notches, or other physical features. The padding layercan also vary in thickness, as may be desirable. In other embodiments,the padding layer is extruded as a solid layer. Post-extrusionmanufacturing processes (i.e., die cut, perforating, etc.) can beperformed on to create the desired format of the padding layer.

Non-limiting illustrations of example head guards are provided in FIGS.42-58 . As is to be appreciated, the figures are not necessarily drawnto scale, but rather depicted to convey example structures,configurations and/or relative positionings of various layers andcomponents of the illustrated head guards.

Referring first to FIG. 42 , a perspective view of an example head guard1300 is depicted. FIG. 43 depicts a cross-sectional view of the headguard 1300 taken along line 43-43 in FIG. 42 . The head guard comprisesan outer fabric layer 1320 and an inner fabric layer 1360. In theillustrated embodiment, an elastic member 1396 is coupled to the lowerperiphery of the head guard 1300. In this embodiment, a padding layer1340 is positioned between the outer fabric layer 1320 and the innerfabric layer 1360. The padding layer 1340 can be coupled to the outerfabric layers 1320 and/or an inner fabric layer 1360 through any of avariety of coupling techniques, such as stitching, gluing, riveting,heat welding, ultrasonic welding, and so forth. In the illustratedembodiment, the outline shape of the components of the padding layer1340 generally mimics the outline shape of the components of the innerand outer layers 1320, 1360 (i.e., triangular). However, this disclosureis not so limited. In some embodiments, the inner and outer layers 1320,1360 can be of a first shape while the padding layer 1340 can be of adifferent shape. While the padding layer 1340 is depicts as beinggenerally planar for illustration purposes, it is to be appreciated thatany suitable structure of padding layer 1340 can be utilized, asdescribed herein. By way of example, padding layer 1340 can beperforated or mesh, have multi-dimensional features (such as ribs ornubs), and so forth.

FIG. 44 depicts an example head guard in a relaxed state (shown as headguard 1400A) and an outwardly expanded state (shown as head guard1400B). The padding layer 1440 comprises a plurality of segments thatare positioned between an outer layer 1420 and an inner layer 1460. Insome embodiments, one or more segments of the padding layer 1440 can bepositioned so that they are visible to an observer (i.e., positioned onthe outer surface of the outer layer 1420 or the inner surface of theinner layer 1460). The padding layer 1440 in FIG. 44 is coupled to theouter layer 1420. In some embodiments, the padding layer 1440 canadditionally or alternatively be coupled to the inner layer 1460. Asprovided above, a variety of different techniques can be used to couplethe padding layer 1440 to the head guard 1400. Once coupled to the headguard, the padding layer 1440 can define a plurality of spacings, whichare devoid of the padding layer (shown as 1480A, 1480B). While thespacings 1480A, 1480B are depicted as being generally rectangular, thisdisclosure is not so limited. As is to be appreciated, depending on theshape of the padding layer 1440 and the shape of the head guard 1400A,1400B, the shape of the spacings can vary. The shape of the spacings canalso vary depending on whether the head guard is in a relaxed state oran expand state. Since the spacings 1480A, 1480B are not coupled to thepadding layer 1440, they are generally free to flex and expand. As shownin head guard 1400B, the spacings 1480B have expanded when the headguard 1400B is in the expanded state. This expansion, and the resultingcompressive forces generated by the spacings 1480B can help to maintainthe head guard 1400B on a wearer's head.

FIGS. 45A, 45B, 46A, and 46B depict example arrangements of paddinglayers for dome-shaped head guards. FIG. 45A depicts a partialcross-sectional view of a head guard 1500 having a padding layer 1540comprised of a plurality of segments coupled to an inner surface 1580 ofa layer 1560 through an adhesive, stitching, or any other suitablecoupling technique. The segments of the padding layer 1540 are thereforevisible to an observer that is viewing the inside of the dome-shapedhead guard 1500. By comparison, the head guard 1600 in FIG. 46A has apadding layer 1640 with a plurality of segments having similar shapes asthe padding layer 1540. In this embodiment, however, the segments of thepadding layer 1640 are coupled to the outer surface 1690 of a layer 1620through an adhesive, stitching, or any other suitable couplingtechnique. The segments of the padding layer 1640 are therefore visibleto an observer that is viewing the outside of the dome-shaped head guard1600. FIG. 45B depicts an embodiment of a head guard 1500A in which thepadding layer 1540 substantially covers the inner surface 1580. FIG. 46Bdepicts an embodiment of a head guard 1600A in which the padding layer1640 substantially covers the outer surface 1690. As shown in FIGS. 45Band 46B the padding layers 1540, 1640 can be segmented. The arrangementand configuration of the segments can vary. In certain embodiments, thepadding layers 1540, 1640 are non-segmented. It is also noted that theoverall shape and configuration of the padding layers 1540, 1640depicted in FIGS. 45A, 45B, 46A, and 46B are merely for illustration, asa wide variety of different shapes and configurations can be usedwithout departing from the scope of the present disclosure. Further, insome configurations, a fabric layer can be positioned to cover thepadding layers 1540, 1640 so that they are no longer visible, butinstead are obscured by the surrounding fabric layers.

FIGS. 47-53 depict cross-sectional views of example head guards toillustrate example techniques for coupling a padding layer 1740 to aninner layer 1760 and/or an outer layer 1720. As is to be appreciated,the cross-sectional views can be associated with a variety of differenthead guard configurations, as described herein. For instance, the headguards depicted in FIGS. 47-53 can include, without limitation,dome-shaped head guards, headband-shaped head guards, baseball hat headguards, as well as a variety of other type of head guards. FIG. 47depicts the padding layer 1740 coupled to an inner layer 1760. FIG. 48depicts the padding layer 1740 coupled to an outer layer 1720. FIG. 49depicts the padding layer 1740 coupled to both an inner layer 1760 andan outer layer 1720. FIG. 50 depicts the padding layer 1740 having afirst portion coupled to an inner layer 1760 and a second portioncoupled to an outer layer 1720. FIG. 51 depicts the padding layer 1740coupled to an inner layer 1760 such that the padding layer 1740 is onthe outside surface of the head guard. FIG. 52 depicts the padding layer1740 coupled to an outer layer 1720 such that the padding layer 1740 ison the inside surface of the head guard. FIG. 53 depicts the paddinglayer 1740 having a first portion coupled to an outer surface of aninner layer 1760 and a second portion coupled to an inner surface of theinner layer 1760.

FIGS. 54-55 depict portions of head guards having textured, non-planarpadding layers coupled to an outside surface thereof. Referring first tothe head guard 1800 shown in FIG. 54 , the padding layer 1840 comprisesa plurality of segments coupled to the outside surface and each having aplurality of ribs. While the ribs are depicts as beinghorizontally-oriented, in some embodiments the ribs have any othersuitable orientation, size, and configuration. Referring next to thehead guard 1900 shown in FIG. 55 , the padding layer 1940 comprises aplurality of nodules coupled to the outside surface. While the nodulesare depicts as being cylindrically-shaped, in some embodiments thenodules can be domed, cubed, hexagonal, or a variety other symmetric orasymmetric structures. Depending on the construction of the associatedhead guard, the padding layers 1840, 1940 can be visible to the observerof the head guard or hidden from view by being positioned between twolayers of material.

FIGS. 56-58 depict example portions of padding layers in accordance withvarious non-limiting embodiments. The padding layer 2040 in FIG. 56defines a plurality of apertures 2042, the size of which may be, forinstance, between about 1 mm and 4 cm. While the apertures 2042 areshown as being round, this disclosure is not so limited. In otherembodiments, apertures 2042 can be a variety of other shapes, such astriangular, square, star-shaped, and so forth. In some embodiments,divots or other types of recessed are utilized. The apertures 2042 canbe, for example, punched or cut into the padding layer 2040 (i.e.,perforated) or otherwise created at the formation of the padding layer2040. The size, placement, and arrangement of the apertures 2042 canvary. FIG. 57 , for instance, depicts a padding layer 2140 havingapertures 2142 that are square-shaped and linearly aligned. FIG. 58depicts a padding layer 2240 having nodules 2242 that extend outwardlyfrom a surface of the padding layer 2240. The nodules 2242 can be solid,hollow, or have apertures extending there through, as illustrated.

Head guards in accordance with the presently disclosed embodiments maybe manufactured using a variety of manufacturing techniques, such asultrasonic welding, stitching, gluing, and/or quilting, for example.Stitching can be used to couple an interior fabric layer to an externalfabric layer to create a pocket to house the padding layer. In someembodiments, double needle stitching is utilized to attach variouscomponents of the head guard. With a double stitching technique, twinneedles create parallel double stitching using two needles mounted in aplastic holder. A standard needle shank is added to the plastic holderso it can be inserted in the needle holder on the sewing machine. Oneneedle can be shorter than the other so that a bobbin can catch bothstitches. The head guards can be manufactured in different sizes so thatthey can accommodate both children head sizes and adult head sizes.

The head guards disclosed herein can be used in a wide variety ofendeavors, either as standalone units or in combination with existingprotective gear, including both activities involving contact andnon-contacting activities. Example applications include, withoutlimitation, mixed martial arts, boxing, paintball, lacrosse,racquetball, water polo, ice skating, roller skating, water skiing, windsurfing, surfing, wrestling, rock climbing, ice hockey, roller hockey,basketball, soccer, wrestling masks, motocross, auto racing, cricket,BMX racing, parkour, and volleyball. Additional applications caninclude, without limitation, rodeo (for both riders and clowns), track &field events, cross-country running, hang gliding, bobsledding, andluge, for example. Other applications for the head guards describedherein include, for example, skiing, snowboarding, skateboarding, rugby,polo, equestrian sports, martial arts, and base jumping. In someembodiments, the head guard may be worn as a component under theathlete's helmet. In some embodiments, the head guard may beincorporated into the athlete's apparel. In some embodiments, the headguard can be worn over top of a sporting helmet. In some embodiments,the head guard can be worn without a helmet.

When a head guard is worn under a helmet (such as a football helmet,hockey helmet, bicycle helmet, and the like), an impact delivered to thewearer's head may be reduced as compared to receiving the impact whenwearing the rigid helmet without a head guard. When tested in generalaccordance with to the National Operating Committee of Standards forAthletic Equipment (NOCSAE) Documner (ND) 002-11m12, a head guard wornin combination with various types of football helmets can dissipate animpact force applied to the helmet as measured by severity index. Forexample, a severity index of an impact to a helmet can be higher thanthe severity index of the same impact delivered to the rigid helmet wornin combination with a head guard. Such impact dissipation can also occurwhen worn in combination with other helmets, such as lacrosse helmets,hockey helmets, and batting helmets in accordance with ND 041-11m12, ND030-11m12, and ND 022-10m12, respectively. Such impact dissipation canalso occur when worn in combination with other types of helmets, such asski helmets, for example. As described herein, head guards in accordancewith the present disclosure do not necessarily have to be worn incombination with a helmet. For such uses, an impact delivered to thewearer's head while wearing a head guard may be reduced as compared toreceiving the impact when not wearing a head guard. Moreover, headguards in accordance with the present disclosure do not necessarily haveto be worn with rigid helmets but can be worn in connection withbaseball hats or other types of non-rigid hats. For such uses, an impactdelivered to the wearer's head may be reduced as compared to receivingthe impact when wearing the non-rigid hat without a head guard.

The particular combination of materials for the various layers of headguards manufactured in accordance with the systems and methods describedherein can vary. Below are some non-limiting examples of materialcombinations. As is to be readily appreciated, other combinations areenvisioned and are within the scope of the present disclosure. For somehead guards, one or more layers can comprise about 80-90% polyester orNylon and about 10-20% Spandex or Elastene. In one embodiment, one ormore layers can comprise about 86% polyester and about 14% Spandex. Oneor more layers can also be a mesh-type material for increasedbreathability and ventilation. The layers of the head guard can havevarious fabric weights. In some embodiments, the fabric weight of anouter or inner lay can be in the range of about 5 to about 12 ounces,for example.

In some embodiments, one or more of the fabric layers can comprise about60% polyester and about 40% cotton. In one embodiment, one or morefabric layers can comprise about 100% cotton. In one embodiment, one ormore fabric layers can comprise about 80% polyester and about 20%spandex. In one embodiment, one or more fabric layers can comprise about90% polyester and about 10% Spandex. In one embodiment, one or morefabric layers can comprise about 86% polyester and about 14% Spandex. Insome embodiments, one or more fabric layers can comprise about 100%acrylic. In one embodiment, one or more layers can comprise about 85%acrylic and about 15% nylon.

In some embodiments, one or more fabric layers can comprise about 100%cotton. In one embodiment, one or more fabric layers can comprise about80% cotton and about 20% polyester. Furthermore, various head guards canbe manufactured from colored materials, dyed particular colors, ormanufactured with glow in the dark and/or reflective materials.

In various embodiments disclosed herein, a single component may bereplaced by multiple components and multiple components may be replacedby a single component to perform a given function or functions. Exceptwhere such substitution would not be operative, such substitution iswithin the intended scope of the embodiments. While various embodimentshave been described herein, it should be apparent that variousmodifications, alterations, and adaptations to those embodiments mayoccur to persons skilled in the art with attainment of at least some ofthe advantages. The disclosed embodiments are therefore intended toinclude all such modifications, alterations, and adaptations withoutdeparting from the scope of the embodiments as set forth herein.

What is claimed is:
 1. A head guard, comprising: a plurality ofmulti-layered sidewalls, wherein the plurality of multi-layeredsidewalls are sewn to collectively form a dome, wherein the dome definesa circular opening for a head of a wearer, and wherein each of themulti-layered sidewalls comprises: an inner stretchable fabric layer, anouter stretchable fabric layer; wherein the inner stretchable fabriclayer and the outer stretchable fabric layer collectively define apocket; and a side padding layer non-removably positioned internal tothe multi-layered sidewall in a pocket, wherein the pocket is defined bythe inner stretchable fabric layer and the outer stretchable fabriclayer during manufacturing, wherein at least a portion of the sidepadding layer being is coupled to one or both of the inner stretchablefabric layer and the outer stretchable fabric layer, and wherein thepadding layer consists essentially of a rate dependent padding material;and wherein the side padding layer of one of the plurality ofmulti-layered sidewalls is discontinuous from the side padding layer ofan adjacent one of the plurality of multi-layered sidewalls, and whereinthe inner stretchable fabric layer and the outer stretchable fabriclayer are expandable from a relaxed state to and an expanded state. 2.The head guard of claim 1, wherein the padding layer is coupled usingone or more of stitching, heat welding, and an adhesive.
 3. The headguard of claim 1, wherein the side padding layer is stitched to theinner stretchable fabric layer and the outer stretchable fabric layer.4. The head guard of claim 1, consisting of four multi-layeredsidewalls.
 5. The head guard of claim 1, wherein the side padding layeris an open-cell side padding layer that is stitched to only the innerstretchable fabric.
 6. The head guard of claim 1, wherein the sidepadding layer is an open-cell side padding layer that is stitched toonly the outer stretchable fabric.
 7. The head guard of claim 1, whereinthe side padding layer is an open-cell side padding layer that isstitched to the inner stretchable fabric and the outer stretchablefabric.
 8. A head guard, comprising: a first triangular multi-layeredsidewall and a second triangular multi-layered sidewall, wherein a firstportion of the first triangular multi-layered sidewall is sewn to afirst portion of the second triangular multi-layered sidewall tocollectively form at least a portion of a dome, wherein the portion ofthe dome defines at least a portion of a circular opening sized toreceive a head of a wearer, and wherein each of the first and secondtriangular multi-layered sidewalls comprises: stretchable fabric layerscollectively defining a pocket; and a side padding layer, wherein theside padding layer is permanently positioned in the pocket and coupledto the stretchable fabric layers during manufacturing, and wherein theside padding layer consists essentially of a rate dependent paddingmaterial; and wherein the side padding layer of the first triangularmulti-layered sidewall is discontinuous from the side padding layer ofthe second triangular multi-layered sidewalls, wherein the head guard isstretchable between a relaxed configuration and an expandedconfiguration.
 9. The head guard of claim 8, further comprising a thirdmulti-layered sidewall, the multi-layered sidewall comprising:stretchable fabric layers defining a pocket; and a side padding layerpermanently positioned in the pocket and coupled to the stretchablefabric layers, the side padding layer comprising a padding material. 10.The head guard of claim 9, wherein the third multi-layered sidewall issewn to the first triangular multi-layered sidewall or the secondtriangular multi-layered sidewall, or both.
 11. The head guard of claim9, further comprising an elastic band coupled to the first triangularmulti-layered sidewall and the second triangular multi-layered sidewalland positioned proximate to the circular opening of the dome.
 12. Thehead guard of claim 11, wherein the side padding layers of each of thefirst triangular multi-layered sidewall and the second triangularmulti-layered sidewall are substantially triangular.
 13. A head guard,comprising: a plurality of triangular multi-layered sidewalls, whereineach of the triangular multi-layered sidewalls comprise: a firststretchable fabric layer having an inner surface and an outer surface; asecond stretchable fabric layer having an inner surface and an outersurface, wherein the inner surface of the first stretchable fabric layerand the inner surface of the second stretchable fabric layercollectively define a pocket; and an open-cell padding layer having afirst side and a second side, the open-cell padding layer non-removablypositioned within the pocket during manufacturing such that the firstside is proximate to the inner surface of the first stretchable fabriclayer and the second side is proximate to the inner surface of thesecond stretchable fabric layer, wherein the open-cell padding layer isstitched to at least one of the first stretchable fabric layer and thesecond stretchable fabric; and an elastic headband; wherein theplurality of triangular multi-layered sidewalls are assembled to definea dome having a circular opening dimensioned to receive a head of awearer; wherein each of the plurality of triangular multi-layeredsidewalls is attached to an elastic band; and wherein the elastic bandencircles the circular opening.
 14. The head guard of claim 13, whereinthe plurality of triangular multi-layered sidewalls comprises at leastfour multi-layered sidewalls.
 15. The head guard of claim 13, whereinthe open-cell padding layer is stitched to only the first stretchablefabric layer.
 16. The head guard of claim 13, wherein the open-cellpadding layer is stitched to only the second stretchable fabric layer.17. The head guard of claim 13, wherein the open-cell padding layer isstitched to both the first stretchable fabric layer and the secondstretchable fabric layer.